SAIPEM REFINING AND PETROCHEMICAL

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1 SAIPEM SpA Via Martiri di Cefalonia, San Donato Milanese Milan - Italy SAIPEM.COM SAIPEM REFINING AND PETROCHEMICAL Saipem. Engineering Energy

2 60 YEARS OF EXPERIENCE IN THE DOWNSTREAM SECTOR SAIPEM CAPABILITIES Saipem is active THROUGHOUT THE ENTIRE DOWNSTREAM CHAIN * UPSTREAM ** PRODUCT EXPORT PIPELINES ** OIL PIPELINES FOR IMPORT Oil Terminals CRUDE OIL DISTILLATION AND UPGRADE AMERICAS REFINERY UNITS 46 PETROCHEMICAL UNITS 12 MIDDLE EAST REFINERY UNITS 248 PETROCHEMICAL UNITS 17 CIS REFINERY UNITS 2 PETROCHEMICAL UNITS 2 PETROCHEMICAL FROM REFINING INTERMEDIATE AFRICA REFINERY UNITS 113 PETROCHEMICAL UNITS 5 FAR EAST AND OCEANIA REFINERY UNITS 54 PETROCHEMICAL UNITS 26 EUROPE REFINERY UNITS 470 PETROCHEMICAL UNITS 102 THE COMPLETE OIL AND GAS EPC SERVICE PROVIDER EPC PROJECTS INDIVIDUAL REFINING AND PETROCHEMICAL UNITS BUILT GRASS ROOTS REFINERIES BUILT COUNTRIES * Upstream brochure available on request ** Pipelines brochure available on request 2 3

3 TECHNOLOGICAL SKILLS AND EXPERIENCE Saipem boasts long lasting agreements and alliances with the world s leading licensors, offering innovative, reliable and commercially proven technologies. REFINERY PLANTS CONTINUING AND BUILDING ON THE SNAMPROGETTI TM LEGACY. The commitment to always deliver the most effective solutions also from the point of view of technology is one of the organisation s key missions. The strategic focus of conducting detailed studies to evaluate, compare and select the licensed technologies by assessing the technical, operational and economic aspects that will ultimately benefit both the project implementation and plant operation allows Saipem to contribute significantly to its clients projects starting from the conceptual phase. Saipem s extensive experience in optimising the integration of process technologies within large and complex EPC projects, including the development of synergies with efficient utilities and offsites, delivers exceptional value with tailored solutions on a specific project basis. Constantly ensuring its engineering and technology expertise is updated enables Saipem to continuously support clients during the life of the plant to improve performance - also by introducing actual innovations - and staying up to date with changing markets and regulation requirements. SAMIR MOHAMMEDIA REFINERY: RESIDUE UPGRADING AND PRODUCT IMPROVEMENTS Marocco Vacuum unit Hydrocracker unit Gasoil HDS unit Hydrogen unit 54,300 bpsd 36,000 bpsd 55,000 bpsd 102,000 Nm 3 /h FROM TECHNOLOGY SELECTION TO SUCCESSFUL DELIVERY OF COMPLETE PROJECTS PROJECT DESCRIPTION Sulphur Plant units 2x253 t/d The refinery was built by Snamprogetti in 1963 and, during the following decades, it went through three subsequent phases of expansion in 1972, 1978 and The plant was fed with crude oil imported through the adjacent port of Mohammedia and produced finished products for the domestic Morocco market, with a crude oil refining capacity of 6.25 Million Tons per year (around 130,000 BPSD). The upgrade, which was completed between 2009 and 2010, resulted in an increase for the refinery in medium distillate product yields along with product specification improvement. Back in the 60s this Project set an important cornerstone of Saipem s way of doing business by making local content and added value the centre of attention of the host countries by utilizing high percentages of local manpower Inauguration by Enrico Mattei, Eni President, of the first Samir refinery 4 5

4 PETROCHEMICAL A STRONG INTEREST IN PETROCHEMICALS WITH THE PRIORITY BEING OLEFINS, POLYOLEFINS, ELASTOMERS AND THE MAIN INTERMEDIATE PRODUCTS. QATOFIN RAS LAFFAN POLYETHYLENE PROJECT PETROCHINA SBR/SSBS ELASTOMERS COMPLEX Hours of engineering Smh erection work 400,000 1,150,000 10,500 m 3 7,300 tons Styrene-Butadiene Rubber Styrene-Butadiene Rubber 60,000 tpa 40,000 tpa 50,000 tpa 30,000 tpa Concrete Styrene-Butadiene Rubber Qatar Steel work and Piping China Styrene-Butadiene Rubber The plant has a capacity of 450,000 tpa of polyethylene using Univation technology and is one of the largest in the world on a single reaction line with the possibility of increasing to 600,000 tpa. Main features Lifting and positioning of large items carried out with the plant already in an advanced state of assembly. Implementation of the enclosed flare solution instead of the conventional stack flare/ground flare allowing for the flare to be installed very close to process units in order to fit in a small size area. World s largest capacity extruder (2009). Pneumatic conveying system for product transfer from pelleting unit to logistic terminal with large capacity associated with the long distance. Improvement in the hydrocarbon recovery system adopting the membrane technology integrated with the Licensor Unit. EPC Contract Lump Sum Turn Key Contract Start-up 2009 The project is part of a major development programme of the mega size Dushanzi Integrated Refinery and Petrochemical complex, which dates back to The plant, based on Polimeri Europa s (Versalis) Technologies, consists of four reaction lines and six finishing lines. Key constraints were mainly due to the severe winter climatic conditions, with temperatures exceeding minus 30 C. This issue implied to customising the Process Design Package in accordance with the Licensor s instructions in order to implement a different solvent to avoid icing problems as well as specific detailed engineering design regarding the winterization aspects. Another challenge was the simultaneous presence of numerous contractors engaged in the construction of the other units. This involved intense efforts to interface and coordinate effectively with teams from all over the world. Saipem also provided technical assistance on site and staff training. EPS Contract Lump Sum Turn Key Contract Start-up

5 GRASSROOT REFINERY from grass roots to operation through effective design with safe execution Saipem offers a complete range of project definition and execution services: from feasibility and conceptual studies to complex integrated solutions combining design, engineering, procurement, field construction, fabrication, commissioning and maintenance AEGEAN REFINERY PROJECT Turkey PROJECT DESCRIPTION Hydrocracker Diesel Hydrotreater Hydrogen Saturated Gas Plant 66,000 bpsd 68,000 bpsd 160,000 Nm 3 /h 48,103 bpsd The scope of work includes 15 Process Units, 10 Auxiliary units and Utilities plus offsites with 3 marine terminals for the import of crude oil and export of final products. The refinery is located adjacent to the Petkim Petrochemical Complex to which it will will provide the main feedstock for petrochemical chains. The site of the plant presented a high degree of challenge due to its configuration on different heights needing multilevel site-reshaping and marine terminal reclamation. EPC LSTK Contract 8 9

6 BOTTOM OF THE BARREL A PIONEER IN THE DEVELOPMENT OF A NOVEL PROCESS TO CONVERT ALMOST COMPLETELY ANY TYPE OF HEAVY OR UNCONVENTIONAL RESIDUE INTO LIGHT PRODUCTS AND DISTILLATES. MODULARIZATION A NEW AND POPULAR WAY OF building even very complex processing plants, in order to facilitate construction in remote and harsh areas to reach frontier markets. EST: THE FIRST INDUSTRIAL APPLICATION WHEN SHOULD WE MODULARIZE? Capacity 24,000 bpsd 17,000 ton 1,300 km 300 mm Equipment weight Italy Instrument cabling Reactor Thickness Easy Plentiful Benign LOGISTICS SITE CONSTRUCTION LABOR SITE WORKING CONDITIONS Stick Built Modularization Difficult Not Sufficient Severe Saipem s extensive know-how in bottom of the barrel hydroconversion was applied in the development of EST, Eni Slurry Technology, a revolutionary refining process that allows almost complete conversion of heavy feedstock into lighter components. EST is based upon an innovative hydro-conversion process scheme featuring a nanodispersed (slurry) non-aging catalyst and a homogeneous and isothermal slurry bubble column reactor. Saipem completed the Basic Design Package and FEED of the first full scale commercial plant in 2008, then performed Detailed Design, procurement services and construction supervision during site activities completed in 2013 with the unit start-up. EST is licensed by Eni; Saipem is the sole authorized contractor for the preparation of the Basic Design Package. As some projects present logistic difficulties in performing work at site, the utilization of a Module Construction Approach can help to reduce the construction manhours at site thus mitigating the risk and time impact associated with site specific limitations. Saipem has performed module construction for several projects to mitigate constraints such as security at site, climatic conditions and lack of manpower availability in the host country. During the preliminary constructability phases of a project, an analysis is performed to determine if the project would benefit more from a module construction or a standard stick built approach

7 HORIZON OIL SANDS PROJECT (SECONDARY UPGRADER) ESCRAVOS GAS TO LIQUID PROJECT Canada Gas Oil Distillate Weight of plant modularization 44,800 bpsd 29,200 bpsd 54% Nigeria Single Heaviest Module Total Module Weight Weight of plant modularization 2,500 tons 22,000 tons 50% The Combined Hydrotreaters Unit, licensed by UOP, consists of two reactors in parallel with a distillate feed to one reactor and a gas oil feed to the other. The reactor effluents join at common separation and stabilization sections hence all equipment downstream from the Hot Separator are common. The Unit was engineered with an extensive level of modularization (Piperacks and Equipment modules). A total of 63 modules, Alberta size, were fabricated in less than 9 months at Saipem fabrication yard in Edmonton (Alberta, Canada) and delivered to the CNRL Horizon Site by June 2016, in line with the project baseline schedule. The scope of the project is a Gas to Liquids Processing Facility utilizing Sasol Fischer Tropsch & Chevron technology to convert 320 MMSCFD of natural gas to approximately 34,000 bpd of of product, consisting of 80% diesel blend and 20% naphtha, for export. The project met a government mandate to eliminate gas flaring in the oil and gas sector. In order to simplify construction at site, with little available space and with a shortage of skilled labour, 23 very large modules (average weight about 1,000 t with the largest module weighing 2,500 t) were built in UAE and Thailand fabrication yards, under Saipem s overall management, then shipped to the site for local erection. Modules were completed with steelwork, equipment, piping, electrical, instruments painting, fireproofing and insulation, corresponding to around 50% of the total weight of the plant

8 OIL TERMINALS Oil terminals represent a logistic challenge due to the large volume of material and equipment to be mobilized. Oil terminals are a strategic asset that are needed both in refineries and import/export terminals. TOUT LUI FAUT REFINERY EXPANSION PROJECT AL ZOUR REFINERY PROJECT - STORAGE TANKS FARM Vacuum Distillation 15,000 bpsd Storage tanks 66 Visbreaker 2,700 bpsd Steel plates 75,000 mt Hydrocracking 10,330 bpsd Concrete m 3 Suriname Hydrogen Production (HPU) including PSA Catalytic Reformer 24,999 Nm 3 /hr 3,100 bpsd Kuwait Piping Cables for power and control systems 40,000 mt 2,000 Km The key objective of the project was to increase the refinery capacity from 7,000 BPSD to 15,000 BPSD with the overall objective being the production of diesel, gasoline and fuel oil as the main products, as well as the maximization of EURO IV through the installation of new systems with a high technological content. Saipem s scope of work included the design and execution of new processing units, new and revamped utility systems and new storage facilities. The execution was based on a modularization approach with the fabrication of pre-assembled racks, units and spools. The project was completed in The project consisted of Engineering, Procurement, Construction, Pre-Commissioning and Assistance during Commissioning/Start-up/Performance Testing of tanks for a storage capacity of up to 2,600,000 m 3 of feed oil and refined products. Related facilities such as buildings, pipe racks, pipelines, water systems and control systems for the Al-Zour refinery were also included together with 20 Km of roads outside the refinery for use as public roads. Photo courtesy of Staatsolie 14 15